Electrodes, electrochemical cells, and methods of forming electrodes and electrochemical cells

Abstract

Electrodes and methods of forming electrodes are described herein. The electrode can be an electrode of an electrochemical cell or battery. The electrode includes a current collector and a film in electrical communication with the current collector. The film may include a carbon phase that holds the film together. The electrode further includes an electrode attachment substance that adheres the film to the current collector.

What is claimed is: 
     
       1. A method of forming an electrode comprising:
 providing a current collector coated with a layer of a first electrode attachment substance on a first side of the current collector, wherein the layer of the first electrode attachment substance is in a substantially solid state; 
 subsequently placing a first solid film comprising electrochemically active material on the current collector coated with the layer of the first electrode attachment substance such that the layer of the first electrode attachment substance is sandwiched between the current collector and the first solid film; and 
 heating the layer of the first electrode attachment substance to adhere the first solid film to the current collector, wherein portions of the first solid film penetrate the layer of the first electrode attachment substance and come in direct contact with the current collector. 
 
     
     
       2. The method of  claim 1 , further comprising:
 providing a second electrode attachment substance on a second side of the current collector, wherein the second electrode attachment substance is in a substantially solid state. 
 
     
     
       3. The method of  claim 2 , further comprising:
 placing a second solid film comprising electrochemically active material on the second electrode attachment substance such that the second electrode attachment substance is sandwiched between the current collector and the second solid film. 
 
     
     
       4. The method of  claim 3 , further comprising:
 heating the second electrode attachment substance to adhere the second solid film to the current collector. 
 
     
     
       5. The method of  claim 4 , wherein heating the first electrode attachment substance and heating the second electrode attachment substance occur simultaneously. 
     
     
       6. The method of  claim 1 , wherein providing a current collector comprises:
 coating the current collector with a polymer solution on the first side of the current collector; and 
 drying the polymer solution to form the layer of the first electrode attachment substance. 
 
     
     
       7. The method of  claim 2 , wherein providing a second electrode attachment substance comprises:
 coating the current collector with a polymer solution on the second side of the current collector; and 
 drying the polymer solution to form the second electrode attachment substance. 
 
     
     
       8. The method of  claim 1 , wherein providing a current collector comprises:
 providing a polymer resin on the first side of the current collector; and 
 extrusion coating the polymer resin to form the layer of the first electrode attachment substance. 
 
     
     
       9. The method of  claim 2 , wherein providing a second electrode attachment substance comprises:
 providing a polymer resin on the second side of the current collector; and 
 extrusion coating the polymer resin to form the second electrode attachment substance. 
 
     
     
       10. The method of  claim 1 , wherein the first electrode attachment substance comprises a polymer that is not soluble in a nonaqueous electrolyte solution. 
     
     
       11. The method of  claim 10 , wherein the nonaqueous electrolyte solution comprises a carbonate solvent. 
     
     
       12. The method of  claim 10 , wherein the polymer comprises polyamideimide, polyvinylidene fluoride, polyethylene, or polypropylene. 
     
     
       13. The method of  claim 1 , wherein heating comprises heat laminating. 
     
     
       14. The method of  claim 1 , wherein heating comprises roll pressing or flat pressing.